Machine for making building panels



p 1958 R. L. ALTSCHULER 2,852,807

MACHINE FOR MAKING BUILDING PANELS Filed May 11. 1954 2 Sheets-Sheet 1 mom compnesso AIR CYLLNDER 56 ROBERT L. ALTS'CHULER Sept. 23, 1958 R. L. ALTSCHULER 2,852,807

MACHINE FOR MAKING BUILDING PANELS Filed May 11. 1954 2 Sheets-Sheet 2 a ll I 6 FROM coMPRzssED Z J Am cvuuoca 9 United States Patent 2,852,807 MACHINE FOR MAKING BUILDING PANELS Robert L. Altschuler, Bronx, N. Y.

Application May 11, 1954, Serial No. 429,095

4 Claims. (Cl. 18-5) This invention relates to a machine for making building panels of the type set forth in my co-pending application, Serial No. 337,514, filed on February 18, 1953.

It is an object of the present invention to provide a machine for making building panels which will economically and accurately manufacture the building panels.

In the manufacture of prefabricated building panels it is desirable for use as little material as possible consistent with proper strength for a structure of this type. In order to reduce the material required, a hollow core panel is indicated. Not only does the saving in material cut down cost, but a reduction in weight is also achieved, making it possible to handle the panels with fewer personnel. The void in the center of the panel also contributes to the insulative qualities of the panel. In some instances it may be desirable to fill the void with insulating material such as fiberglass, rockwool, foamed plastic, or the like. i

It is, accordingly, another object of the present invention to provide a machine which will manufacture prefabricated building panels of the above type having a hollow core.

It is another, object of the present invention to provide a machine for making building panels which will manufacture one-half the panel during one cycle of operation, the plane of division between the two panel halves lying along a plane parallel to the two outer faces of the panel and midway therebetween.

It is still another object of the present invention to provide a machine for making building panels having hollow cores wherein the need for a heavy press to compress the mold is eliminated, a relatively light press being used to obtain the initial stage of compression, anda flexible, expandible air cell being provided, subjecting the material in the mold to high pressure similar to that obtained from a large hydraulic press.

Other objects of the present invention are to provide a machine for making building panels which is of simple construction, inexpensive to manufacture, has a minimum number of parts, is easy to use and efficient in operation.

For further comprehension of theinvention, and-of the objects and advantages thereof, reference will be had to the following description and accompanying drawings, and to the appended claims in which the various novel features of the invention are more particularly set forth.

In the accompanying drawings forming a material part of this disclosure:

.Fig. 1 is a perspective view of a building panel produced by the present invention, a corner thereof being shown broken away to show the interior hollow core.

Fig. 2 is a perspective view of a building panel half formed from the present invention, a corner thereof being .shown broken away to show the 2,852,807. Ce Patented Sept. 23, 1958 shown broken away to show the interior construction thereof.

Fig. 4 is a perspective view of a building panel making machine embodying the features of the present invention, shownpartly in section to show the interior construction thereof.

Fig. 5 is a perspective view of a panel half formed from a modified form of the present invention, a corner thereof being shown broken away.

Fig. 6 is a perspective view of the bottom half of a mold forming a part of the present invention and used to form the panel half of Fig. 5, a corner thereof being interior construction thereof.

Fig. 7 is a perspective view of the modified form of the invention used to produce the panel half of Fig. 5, shown partly in section to show the interior construction thereof.

The machine as it will be described, manufactures one-half the panel at a time, the line of division between the two half panels lying along a plane parallel to the two faces of the panel and midway therebetween. The half panels are then joined together with a suitable adhesive. This machine is designed to form these panels of a bulk material such as sand, sawdust, wood, fiber, wood chips, Verrniculite, Perlite, etc., and a suitable bonding material such as plastic resin or cement.

It is a well known fact that in compressing bulk material, such as sawdust or wood chips, during the initial stages of compression a relatively small amount of pressure produces a relatively large decrease in volume; to-

facts are considered in the design of the instant machine suitable adhesive.

with the result that the need for a heavy press to compress the material is eliminated.

A relatively light press is used to provide the initial stages of compression and to land or close the mold to provide what will be the final external dimensions of the half panel. That portion of the mold forming the hollow core of the panel is built of a flexible, expandable material such as rubber or elastic plastic, this rubberlike material being shaped to form an air cell. This air cell is connected by suitable ducts to a source of air pressure.

During closing of the mold very little air pressure is maintained within the air cell so that if too much material is includedin the mold, the excess in volume is compensated for by a contraction in size of the air cell.

After the mold is securely locked, the pressure in the air cell is raised by admitting air under pressure from the pressure source. to a relatively great pressure, similar to that which is obtained from a large hydraulic press.

Referring now to Figs. 1 through 4, there is shown a prefabricated building panel referred to collectively as 10 and made up of a pair of identical panel halves 11 secured together along their adjacent edges 12 by means of a As shown in Fig. 2, each panel half 11 consists of a fiat central rectangular portion 13 formed with a peripheral, rectangular ridge 14, the panel extending outwardly from the ends of ridge 14 in a thickened rectangular portion 15 and from the sides of the ridge 14 in a thickened rectangular portion 16 having an inwardly flared surface 17 contacting the base of ridge 14. As

shown in Fig, 1, when the two halves 11 are secured together along the adjacent edges of the ridge 14, the cooperating portions 16 and surfaces 17 will form dovetailed grooves adapted to be filled with concrete, when disposed adjacent the corresponding dovetail grooves of This subjects the material in the mold the adjacent panel, as set forth in my co-pending application, Serial No. 337,514.

-In order to form the panel halves 11, a machine, referred to collectively as 1-8, is provided and includes a four-sided rectangular housing 19 open at top and. bottom (Fig. 4). A rectangular plate 24 constituting a partition wall and: forming the bottom of the moldfits within the housing 19 and is adapted forvertical movement there-.v withinin the; direction of the arrow of 'Fig. 4. As shown in Fig. 3, the bottom plate 20 fixedly mounts at each end the metal ridges 21 and at each side the metal ridges 22 completing'the solid portion of the lower mold half.

The central portion of the plate 20.. is. provided with a, hollow, rectangular main air cell 23 of a flexible, expandible material, such as rubber or elastic plastic, the cell 23 being; completely closed" except for air inlet and outlet; lines. It will be noted that the ends of air cell 23 are freely spaced from the ridges 21 whereby toform the end ridges 14 of panel 11, the sides of air cell 23 being likewise freely spaced from the ridges 22 for the same purpose. An air inlet 24 extends through the plate 20 and into the interior of air cell 23, the lower end of inlet 24 being connected to a suitable source of compressed air, the connection including suitable valves and gauges for controlling the pressure within the air cell 23. A pair of secondary, longitudinal air cells '25 are disposed adjacent the inner faces of the ridges 22, the air cells 25 being freely spaced from the sides of air cell 23 and provided each with an inlet 26 for compressed air similar to inlet 24. It will be noted that the upper surfaces of air cells 25 are downwardly inclined toward the. top of ridges 2 2, whereby-to provide the surfaces 17 previously referred to.

The housing 19 at suitable intervals is provided at its bottom portion with vertical cylindrical openings 27 con tinuing upwardly through the top portion thereof as cylindrical openings 28 of less diameter than the openings 27 whereby to provide shoulders 29. An intermediate rectangular frame 30 rests on the upper edges of housing 19, the intermediate frame 30 being provided with openings 31 aligned with the openings 28 of housing 19. A cover plate 32 fits on to the intermediate plate 30 and is provided with openings 33 aligned with the openings 31 in plate 30. Suitable means, not shown, will be provided" for releasably retaining the cover 32 in the position of Fig. 4.

It will be readily apparent to those skilled in the art that the air cells 23 and 25 may be replaced with rigid, metallic counterparts of identical size and shape when a Press of sufficient capacity is available, without departing from the scope of the invention.

As a means of moving the bottom plate 20 upwardly towards the top cover plate 32, bars constituting brackets 34 are fixedly connected at their upper ends to the bottom of plate 20, the lower ends of the brackets 34 being connected by transverse bar members 35.

One such transverse member 35 is provided for each laterally aligned pair of openings 27 within housing 19, the ends of the transverse members 35 extending outwardly therebelow and fixedly mounting shafts 36 which extend upwardly through the aligned openings 27, 2'8, 31 and 33, as shown in Fig. 4. A collar 37 is secured at the bottom of each shaft 36 and serves to abut the lower end of an expansion spring 38, the upper end of each expansion spring 3'8 abutting a shoulder 29. Suitable means, not shown, will be provided for moving the transverse members 35 upwardly whereby to compress the plate 20 toward the cover plate 32 with the material therebetween. The springs 38 will normally retain the bottom plate 20 in freely spaced relation to the cover plate 32 but will permit the upward movement of plate 20 upon the application of external pressure.

With the parts in the disposition of Fig. 4, the premixed bulk material and binder are poured into the bottom half of the mold and readily fill most of the crevices between the air cell 23, ridges 21 and secondary cells 25. The collars 37 are adjustable, controlling travel of the lower portion of the mold relative to plate 32- and controlling thereby the thickness of the finished product.

For optimum distribution of the material within the lower half of the mold, a strike board will be used. The cover plate 32 is then positioned and secured in place by suitable means, whereupon the bottom plate 20 is advanced upwardly bymeans of the brackets 34, transverse members and external pressure until the final position of the plate 29 has been achieved. This provides the initial stage of compression as well as the final external dimensions of the half panel. The mold is then locked. The pressure in the air cells 23 and 24 is then raised by admitting air under pressure from the pressure source. This subjects the material in the mold to relatively great pressure, similar to that obtained from a large hydraulic press. The pressure required will vary depending on the bulk material and the binder used. When plastic resin binders are used, the locked mold 18 is sent through an oven, not shown, which is maintained at the proper temperature for good bonding. Allowance must be made for they rise in pressure in the air cells 23 and 25 caused by the increased temperature. Allowance must also be made for the venting of steam caused by the heating of those materials which contain moisture. Suitable holesfor the venting of such steam should be provided along the parting line.

could be readily cleaned out when the mold comes apart.

In using the elastic air cells 23 and 25, the size of the hollow core is not always uniform or consistent. However, as long as the wall thickness of the panel is sufiicient, the dimensions of the hollow core are not critical, Those surfaces that are used to mate the two half panels 11 together and to similar panel units, it will be noted, are formed on the solid part of the mold.

Intermediate plate 30 is used to form a right angle bend in the ply material and in effect caused the ply material to be wrapped around the face of the panel 10 to make it additionally waterproofing.

The material employed for the panel 10 can be classified in two. categories:

(1) Resinous lbonded material which requires heatand pressure for cure. Examples are resin-bonded sand, sawdust, wood chips, Perlite, Vermiculite.

(2) Concrete or plasterlike materials.

The surface of panel 10 can be left plain, painted or veneered with a decorative material, such as wood, cloth, paper or the like. are used the veneer surfacing can be temporarily fastened to the upper surface of the mold. When the mold is closed and the panel material is compressed, bonding will take place between the veneer and the panel material. When wet Portland cement or similar binders are used, the panel should be cured first. The veneer can then be applied, using a suitable adhesive under heat and pressure.

Referring now particularly to Figs. 5 through 7, there is shown a modified form of the present invention designed to form a panel half 11 having a window or door opening.

Window and door openings'will have a taper that precludes having the portion of the mold forming the window or window opening mounted on the bottom of the mold. Therefore, in order for the panel to clear the mold, it will be necessary for the portion of the mold which forms the door or window opening to be mounted on the upper half of the mold. Otherwise it would be impossible'to remove the panel half from the mold.

However, if the door or window portion of the mold (core) were permanently mounted on the upper half of the mold, some of the resin mixture poured into the bottom of the mold would be trapped between the door or window core and the bottom of the mold, preventing Thus, any resin plastic or resinous by-. product exuded through such holes by steam pressure When resin-bonded panel materials the closing of the mold. The door or window core must therefore the provided as a third, separable part of the mold. It must be mounted on the bottom of the mold when pouring the mixture, but is withdrawn with the upper half of the mold after curing the half panel.

In this form a half panel 11 is provided having a central door or window opening 39 surrounded by an upwardly extending ridge 40, the inner faces'of the ridge 40 being tapered inwardly away from the flat portion 13. .In other respects the half panel 11 is the same as the half panel 11, and like reference numerals identify like parts throughout the several views.

In order to produce the window opening 39 and ridge 40, the central air cell 231* (Fig. 6) is now formed with a central opening 41.

The modified machine 18*- (Fig. 7) is now provided with a cover plate 32 having a rectangular opening 42, angle brackets 42 being secured to each side of opening 42 on cover plate 32 A trough-shaped hollow core 44 having vertical side walls 45 and end walls 46 is adapted to fit snugly downwardly within opening 42, the lower portions of side walls 45 and end walls 46 being inwardly flared toward the bottom 47, the inwardly flared portions of the side walls 45 and end walls 46 providing the inner taper of the ridge 40 of panel 11. In use, the machine 18 will be used in the same manner as the machine 18, the core 44 being placed on plate 20 before adding the material. The core 44 is properly positioned by means of pins 50 and openings 51. After the material has been added, the cover plate 32 will be added, and after the initial compression, the device will be locked as in the first form. However, after curing, with the upper portions of side walls 45 connected to angle brackets 43 through the elongated aligned openings 48 and 49 in walls 45 and brackets 43 respectively, the core 44 will be removed along with the cover plate 32*.

In other respects the form of the invention shown in Figs. 5 through 7 is the same as that shown in Figs. 1 through 4, and like reference numerals identify like parts throughout the several views.

While I have illustrated and described the preferred embodiments of my invention, it is to be understood that I do not limit myself to the precise constructions herein disclosed and the right is reserved to all changes and modifications coming within the scope of the invention as defined in the appended claims.

Having thus described my invention, what I claim as new, and desire to secure by United States Letters Patent is:

1. A machine for making plastic bonded panels comprising a hollow housing open at the bottom and top, a lower mold half slidable vertically within said housing, a removable cover forming the upper half of said mold, said lower mold half comprising a movable bottom plate of solid material, ridges around the sides and ends of said bottom plate, a main central air cell of flexible, expandible material on said bottom plate, the sides and ends of said air cell being closely spaced from said end and side ridges, secondary elongated air cells disposed alongside the inner faces of said side ridges, said secondary air cells being closely spaced from the sides of said main air cell, means for supplying compressed air to said central and secondary air cells, said main central air cell having a central opening, a hollow trough-shaped member adapted to fit downwardly into said air cell opening, said trough-shaped member having a bottom wall adapted to rest on said bottom plate, the lower portions of the side and end walls of said trough-shaped member being flared outwardly to the bottom wall, said cover plate having a central opening receiving the upper portions of said trough-shaped member therethrough, and means for releasably securing the upper portions of the side walls of said trough-shaped member to said cover plate.

2. Am'achine' formaking plastic bonded panels comprising a hollow housing open at the bottom and top, a lower mold half slidable vertically within said housing, a removable cover forming the upper half of said mold, said lower mold half comprising a movable bottom plate of solid material, ridges around the sides and ends of said bottom plate, a main central air cell of flexible, expandible material on said bottom plate, the sides and ends of said air cell being closely spaced from said end and side ridges, secondary elongated air cells disposed alongside the inner facesof said side ridges, said secondary air cells being closely spaced from the sides of said main air cell, means for supplying compressed air to said central and secondary air cells, said central air cell having a central opening, a hollow trough-shaped member adapted to fit downwardly into said air cell opening, said troughshaped member having a bottom wall adapted to rest on said bottom plate, the lower portions of the side and end walls of said trough-shaped member being flared outwardly of the bottom wall, said cover plate having a central opening receiving the upper portions of said trough-shaped member therethrough, and means for releasably securing the upper portions out of the side walls of said trough-shaped member to said cover plate, said last-mentioned means comprising angle brackets secured to said cover plate adjacent the sides of said opening therein, the upper portions of the side walls of said trough-shaped member and said angle brackets having longitudinally spaced, aligned openings.

3. A machine for making a building panel comprising a rectangular housing having side and end walls and being open at the bottom, a cover over the top fastened to the top of the side and end walls, a partition wall spanning the space between the side and end walls and being movable up and down therebetween, said partition wall having a ridge extending upwardly along its peripheral edge, said side walls having spaced openings extending therethrough from top to bottom, said openings having restricted and enlarged portions providing shoulders therebetween, means for urging said partition wall downwardly away from the cover, said means including movable frames spaced along the housing, each frame having a flat bar extending transversely of the housing underneath the same, spaced fiat bars extending upwardly from the transverse bars, the upper ends or": the upwardly extending bars being fastened to the partition wall, shafts supported on the ends of the transverse bars and extending upwardly through the openings in the side walls of the housing and compression springs circumposed on the shafts and having one end pressing against the shoulders in said openings and the other end against the transverse bars whereby said transverse bars are urged away from the cover, a flat resilient tubular closed cell supported flatwise on the top surface of the partition wall and covering the major area thereof, the ends of said cell being closely spaced from the end portions of the ridge on the partition wall, elongated rectangular shaped resilient tubular closed cells supported on the partition wall and being closely spaced laterally of the fiat tubular cell, and means for inflating said cells, said partition wall, cells, side and end walls and cover defining a compartment adjustable in height to receive plastic material for forming a panel with a flat base having a ridge extending from one face thereof, on all sides thereof.

4. A machine for making a building panel comprising a rectangular housing having side and end walls and being open at the bottom, a cover over the top fastened to the top of the side and end walls, a partition wall spanning the space between the side and end walls and being movable up and down therebetween, said partition wall having a ridge extending upwardly along its peripheral edge, said side walls having spaced openings extending therethrough from top to bottom, said openings having restricted and enlarged portions providing shoulders.

4 thr e w emme n or-urging sa d par it onwall d w wardly away from the cover, said means including movable frames: spaced along the housing, each frame having a, flat bar extending transversely of the housing underneath the same, spaced flat bars extending upwardly from the transverse bars, the upper ends of the upwardly extending bars being fastened to the partition wall, shafts supported on the ends ofthe transversebars and extend ing upwardly. through the openings in the side walls of the housing and compression springs circumposed on the shafts and having one end pressing against the shoulders in said openings. and the other end against the transverse bars whereby said transverse bars are urged awayfrom the cover, a flat resilient tubular closed cell supported flatwise; on the top surface of the partition walliand coveringthe major area thereof, said cellphaving aflattened O-shape, the ends of the, cell being closely spaced from the end portions of the ridge on the partition wall, elongated rectangular shaped resili nt tubular being supported. on the. partition wall, said. partition wall, cells, trough-shaped device, side and endwalls and cover defining a compartment adjustable in height to receive plastic material for forming a panel having a central opening, with ridges along, its outerand inner peripheral edges.

References Cited in the, fileof this patent UNITED STATES PATENTS 720,718- Maddock et al. Feb. 17, 1903 798,772 Fisher Sept. 5, 1905 995,690, Landis June, 20, 1911' 1,149,669 Manersberger Aug. 10, 1915 1,619,570 Duchernin Mar. 1, 927 2,193,879 Muenzer Mar. 19, 1940 2,394,146 Bruntonet al. Feb.,5, 1946 2,528,643 Dubbs Nov. 7, 1950 2,612,276 Clayton et al. Sept. 30, 1952 2,629,140 Clements Feb. 24, 1953 2,650,412 Dubbs Sept. 1, 1953, 2,699,590 Respess etal. Jan. 18, 1955 FOREIGN PATENTS 35,669 Norway Sept. 11, 1922 

